CN115998034A

CN115998034A - Knitted component with raised structure and method of manufacture

Info

Publication number: CN115998034A
Application number: CN202310091109.XA
Authority: CN
Inventors: 塞缪尔·L·巴蒂斯; 何塞路易斯·马里斯卡尔; 塞斯·M·维贝格; 尼古拉·A·丹比
Original assignee: Nike Innovate CV USA
Current assignee: Nike Innovate CV USA
Priority date: 2018-10-19
Filing date: 2019-07-12
Publication date: 2023-04-25
Also published as: CN112867412B; US11384459B2; US11624134B2; CN112867412A; EP4353886A2; EP3866634B1; EP3866634A1; EP4353886A3; US20200121019A1; WO2020081133A1; US20220298683A1

Abstract

The present application relates to knitted components having raised structures and methods of manufacture. A knitted component includes a first knitted layer of first yarns and a second knitted layer of second yarns. The second knitted layer and the first knitted layer are at least partially coextensive with each other and form a pocket between the first knitted layer and the second knitted layer. The third yarn is positioned at least partially within the pocket and between the first knit layer and the second knit layer. The third yarn includes a first strand and a second strand, the first strand and the second strand having at least one different characteristic. The third yarn is secured to the first knit layer at a first location within the pocket and is secured to the second knit layer at a second location within the pocket and forms an x-shaped configuration.

Description

Knitted component with raised structure and method of manufacture

The present application is a divisional application of application number 201980068401.1, entitled "knitted component having a raised structure and method of manufacturing", having application date 2019, month 07, and 12.

Background

Various articles are formed from textiles. By way of example, articles of apparel (e.g., shirts, pants, socks, footwear, jackets and other outerwear, briefs and other undergarments, hats and other headwear), cases (e.g., backpacks, bags), and upholstery for furniture (e.g., chairs, sofas, car seats) are typically formed at least in part from textiles. These textiles are often formed by weaving or interlacing (e.g., knitting) a yarn or yarns, typically by a mechanical process involving a loom or knitting machine. One particular object that may be formed from textiles is an upper for an article of footwear.

Conventional articles of footwear generally include two primary elements: an upper and a sole structure. The upper is secured to the sole structure and forms a void within the article of footwear for comfortably and securely receiving a foot. The sole structure is secured to a lower surface of the upper so as to be positioned between the upper and the ground. For example, in an article of athletic footwear, the sole structure may include a midsole and an outsole. The midsole may be formed from a polymer foam material that attenuates ground reaction forces during walking, running, and other ambulatory activities to reduce stresses on the foot and leg. The outsole may be secured to a lower surface of the midsole and forms a ground-engaging portion of the sole structure that is formed of a durable and wear-resistant material.

The upper of an article of footwear generally extends along the medial and lateral sides of the foot and around the heel region of the foot over the instep and toe regions of the foot. The entrance to the void on the interior of the upper is typically provided by an ankle opening in the heel region of the footwear. Lacing systems are often incorporated into the upper to adjust the fit of the upper to facilitate the entry and removal of the foot from the void within the upper. The upper may include a tongue that extends under the lacing system to enhance adjustability of the footwear, and the upper may include a heel counter to limit movement of the heel.

Disclosure of Invention

The application also relates to the following items:

1. a knitted component comprising:

a first knit layer comprising a first yarn having a first shrinkage when stimulated;

a second knitted layer at least partially coextensive with the first knitted layer, the second knitted layer comprising a second yarn having a second shrinkage when subjected to the stimulus, the second shrinkage being less than the first shrinkage; and

a third yarn at least partially within a pocket formed between the first and second knitted layers, the third yarn comprising a monofilament yarn and a high tenacity yarn;

wherein the third yarn is secured to the first knit layer at a first location within the pocket and to the second knit layer at a second location within the pocket.

2. The knitted component of item 1, wherein the second knitted layer forms a raised structure by extending away from the first knitted layer when the knitted component is subjected to the stimulus.

3. The knitted component of item 2, wherein the third yarn is visible through the second knitted layer at the raised structure of the knitted component.

4. The knitted component of item 1, wherein the first knitted layer forms a portion of an interior surface of an upper and the second knitted layer forms a portion of an exterior surface of the upper.

5. The knitted component of item 2, wherein the raised structure forms a substantially spherical shape.

6. The knitted component of item 1, wherein the first knitted layer and the second knitted layer are secured to one another adjacent a second region of the pocket.

7. The knitted component of item 1, wherein the third yarn is secured to the first knit layer and the second knit layer by tuck stitches at the first location and the second location within the pocket.

8. A knitted component comprising:

a pod comprising a first knitted layer, a second knitted layer, a raised structure in which the second knitted layer extends away from the first knitted layer, and a pocket formed in the pod between the first knitted layer and the second knitted layer;

a second region, the second region delimiting at least a portion of the pod, the second region having a height less than a height of the raised structures; and

At least one yarn positioned within the pocket between the first and second knitted layers of the pod, wherein the at least one yarn is secured to the first knitted layer at a first location within the pocket and to the second knitted layer at a second location within the pocket, and wherein the at least one yarn comprises monofilament yarns and high tenacity yarns.

9. The knitted component of item 8, wherein the at least one yarn is secured to the first knitted layer at a third location within the pocket and is secured to the second knitted layer at a fourth location within the pocket.

10. The knitted component of item 8, wherein the first knitted layer forms a portion of an interior surface of an upper and the second knitted layer forms a portion of an exterior surface of the upper.

11. The knitted component of item 9, wherein the first position is different from the third position and the second position is different from the fourth position.

12. The knitted component of item 8, wherein the first knitted layer and the second knitted layer are secured to one another at the second region.

13. The knitted component of item 8, wherein the at least one yarn is secured to the first knit layer and the second knit layer at the first location and the second location via tuck stitches.

14. The knitted component of item 8, wherein the raised structure forms a substantially spherical shape.

15. The knitted component of item 8, wherein the at least one yarn is visible through the second knitted layer at the raised structure of the knitted component.

16. A knitted component comprising:

a first knitted layer and a second knitted layer at least partially coextensive with each other;

a pocket formed between the first knit layer and the second knit layer; and

a yarn positioned at least partially within the pocket between the first knit layer and the second knit layer, the yarn comprising a first portion and a second portion, the first portion and the second portion each comprising monofilament yarns and high tenacity yarns;

wherein the first portion of the yarn is secured to the second knit layer at a second location within the pocket, extends from the second knit layer through the pocket to the first knit layer, and is secured to the first knit layer at a fourth location within the pocket;

Wherein the second portion of the yarn is secured to the first knit layer at a first location within the pocket, extends from the first knit layer through the pocket to the second knit layer, and is secured to the second knit layer at a third location within the pocket; and is also provided with

Wherein the first portion of the yarn and the second portion of the yarn form an x-shaped configuration within the pocket.

17. The knitted component of item 16, wherein the first portion of the yarn and the second portion of the yarn are secured to the first knit layer and the second knit layer via tuck stitches.

18. The knitted component of item 16, wherein the first knitted layer forms a portion of an interior surface of an upper and the second knitted layer forms a portion of an exterior surface of the upper.

19. The knitted component of item 16, wherein the second knitted layer forms a raised structure by extending away from the first knitted layer when the knitted component is stimulated.

20. The knitted component of item 16, wherein the first knitted layer and the second knitted layer are secured to one another adjacent a second region of the pocket.

Drawings

Embodiments will be further described with reference to the accompanying drawings. The accompanying drawings, which are included as part of this specification, are intended to be illustrative of exemplary embodiments and should in no way be considered as limiting the scope of the disclosure. Indeed, the present disclosure specifically contemplates other embodiments that are not illustrated but are intended to be included in the claims.

Fig. 1 is an illustration showing a perspective view of an article of footwear incorporating knitted components with raised structures in accordance with certain aspects of the present disclosure.

Fig. 2 is a diagram illustrating a medial side view of the article of footwear of fig. 1.

Fig. 3 is an illustration showing a cross-sectional view of a three-layer knitted component in a flat orientation and prior to a stimulation step in accordance with certain aspects of the present disclosure.

Fig. 4 is a diagram illustrating the knitted component of fig. 3 during a stimulation step in accordance with certain aspects of the present disclosure.

Fig. 5 is a diagram illustrating a side view of a knitted component after a stimulation step in accordance with certain aspects of the present disclosure.

Fig. 6 is a diagram illustrating a top view of a knitted component prior to a stimulation step and corresponding procedural views of a knitting sequence for forming the knitted component in accordance with certain aspects of the present disclosure.

Fig. 7A to 7B are illustrations of exploded views showing a program view of the knitting sequence of fig. 6.

Detailed Description

Various aspects are described below with reference to the drawings, wherein like elements are generally referred to by like reference numerals. The relationship and functioning of the various elements of the various aspects are better understood by reference to the following detailed description. However, the aspects are not limited to those illustrated in the drawings or explicitly described below. It should also be understood that the drawings are not necessarily to scale and that details not necessary for an understanding of the various aspects disclosed herein (e.g., conventional fabrication and assembly) may be omitted in some instances.

Certain aspects of the present disclosure relate to articles formed at least in part from textiles. One example of an article is an article of apparel (e.g., shirts, pants, socks, footwear, jackets and other outerwear, briefs and other undergarments, hats and other headwear, etc.). The article may be an upper configured for an article of footwear. The upper may be used in connection with any type of footwear. Illustrative, non-limiting examples of articles of footwear include basketball shoes, cycling shoes, cross-training shoes, global football (soccer) shoes, american football shoes, bowling shoes, golf shoes, hiking shoes, ski or snowboard boots, tennis shoes, running shoes, and walking shoes. The upper may also be incorporated into non-athletic footwear (e.g., dress shoes, slippers, and sandals).

One aspect of the invention includes a knitted component having a first knitted layer and a second knitted layer that are at least partially coextensive with each other and form a pocket. The third yarn is positioned at least partially within the pocket and between the first knit layer and the second knit layer. The third yarn is secured to the first knit layer at a first location in the pocket and is secured to the second knit layer at a second location in the pocket.

One or more aspects of the present invention provide the advantage of forming a knitted component having at least one raised structure formed from a first knitted layer, a second knitted layer, and a third yarn positioned at least partially between the first knitted layer and the second knitted layer. The third yarn of the knitted component is visible through the second knitted layer at least one location of the at least one raised structure.

One or more aspects of the present invention provide the advantage of forming a knitted component for an upper for an article of footwear having a plurality of raised structures, wherein the color of the raised structures is visible from an exterior surface of the upper and can vary based on the structure, configuration, and location of at least one yarn within the raised structures.

Referring to fig. 1-2, article of footwear 100 may include an upper 102 secured to a sole structure 104. Upper 102 may include a lateral side 106 and a medial side 108. The area of sole structure 104 that engages the footwear of upper 102 may be referred to as a bite line 110. Upper 102 may be fixedly coupled to sole structure 104 using any suitable technique, such as through the use of adhesives, through stitching, and the like. It is contemplated that upper 102 may extend partially or completely around the foot of the wearer and/or may be integral with the sole, and may or may not use an insole. In some embodiments, sole structure 104 may include a midsole (not shown) and an outsole.

The article of footwear 100 may additionally include a throat area 112 and an ankle opening 114, which throat area 112 and ankle opening 114 may be surrounded by a collar 116 and may open into a void 118. Void 118 of article of footwear 100 may be configured to receive a person's foot. Throat area 112 may be generally disposed in midfoot region 120 of upper 102. Midfoot region 120 is generally the region of upper 102 that is located between heel region 122 and toe region 124. In some embodiments, the tongue may be disposed in throat area 112, but the tongue is an optional component. The tongue may be any type of tongue, such as a gusset tongue or a roll (burrito) tongue. If a tongue is not included, the lateral and medial sides of throat area 112 may be joined together. As shown, in some embodiments, article of footwear 100 may include an optional fastening element, such as a lace (which may be associated with lace aperture 126). Any suitable type of fastening element may be used.

Upper 102 may further include one or more structures, including, but not limited to, at least one pod 160 having at least one raised structure 128. Referring to fig. 3-5, pods 160 include at least one side that is bounded by an edge region, such as second region 130. As described in more detail below, a stimulus (e.g., heat or steam) may be applied to upper 102 to form (and/or enhance the loftiness of) at least one raised structure 128. The raised structures 128 may be of various shapes and sizes, and in one example, may be generally spherical structures. The second region 130 may surround the perimeter or at least one side of the raised structures 128 to form pods 160. As shown in fig. 4, a cross-sectional view of knitted component 132 is illustrated with height 130a or in other words thickness, and width 130b of second region 130 being substantially less than height 128a or thickness, and width 128b of raised structures 128.

Pods 160 are formed from two (or more) knitted layers that at least partially overlap and are coextensive with each other, forming pockets 159 between them within pods 160. When exposed to a stimulus (e.g., heat or steam), the second knit layer extends away from the first knit layer to form a raised structure 128 (described in more detail below). The second region 130 that demarcates pods 160 may also be formed from two (or more) layers of knitting (as described in more detail below). The element may be placed within a pocket (e.g., a floating portion of yarn). Raised structures 128 may be disposed at any suitable location on the article of footwear, such as in heel region 122, midfoot region 120, toe region 124, medial side 108, lateral side 106, and/or other locations or combinations thereof. Raised structures 128 may be advantageous to provide footwear 100 with suitable cushioning, stiffness (e.g., without sacrificing flexibility in certain directions), durability, desired aesthetic properties, or other properties. Any suitable number of raised structures 128 may be included. In some embodiments, a plurality of raised structures 128 may be included. In one non-limiting example, as shown in fig. 1 and 2, there may be a plurality of raised structures 128. One example of a raised structure is described in U.S. provisional patent application 62/702,248 filed on 7/23 in 2018, which is incorporated herein by reference in its entirety.

At least a portion of upper 102, and in some embodiments substantially the entire upper 102, may be formed from knitted component 132, which knitted component 132 may be formed on a flat knitting machine, for example, by a weft knitting process. Knitted component 132 may additionally or alternatively form another element of article of footwear 100, such as a underfoot portion. As shown in fig. 3-5, knitted component 132 may have a first side 134 that forms an interior surface of upper 102 (e.g., facing void 118 of article of footwear 100) and a second side 136 that forms an exterior surface of upper 102 (e.g., generally facing opposite first side 134). The first side 134 and the second side 136 of the knitted component 132 may exhibit different properties (e.g., the first side 134 may provide wear resistance and comfort, while the second side 136 may be relatively rigid and provide desired aesthetic characteristics, water resistance, and other advantageous properties mentioned herein). Knitted component 132 may be formed as an integral, unitary element during a knitting process such as a weft knitting process (e.g., using a flat knitting machine or a circular knitting machine), a warp knitting process, or any other suitable knitting process. That is, the knitting process on the knitting machine can substantially form the knitted structure of knitted component 132 without requiring significant post-knitting processes or steps. Alternatively, two or more portions of knitted component 132 may be separately formed as different integral, single piece elements, and then each element attached.

Forming upper 102 with knitted component 132 may provide advantageous properties to upper 102 including, but not limited to, a particular degree of elasticity (e.g., expressed in terms of Young's modulus), air permeability, flexibility, strength, moisture absorption, weight, abrasion resistance, and/or combinations thereof. These properties can be achieved by selecting a particular single or multi-layer knit structure (e.g., a rib knit structure, a single jersey knit structure, or a double jersey knit structure), by varying the size and tension of the knit structure, by using one or more yarns formed of a particular material (e.g., a polyester material, a relatively inelastic material, or a relatively elastic material such as spandex), by selecting yarns of a particular size (e.g., denier), and/or combinations thereof. Knitted component 132 can also provide desired aesthetic characteristics by including yarns having different colors, reflectivities, textures, or other visual characteristics arranged in a particular pattern.

The yarns themselves and/or the knit structure formed by one or more yarns of knitted component 132 may vary at different locations such that knitted component 132 has two or more portions with different characteristics (e.g., portions forming throat region 112 of upper 102 may be relatively elastic while another portion may be relatively inelastic). In some embodiments, knitted component 132 may comprise one or more materials having properties that change in response to a stimulus (e.g., application of steam and/or other forms of heat, moisture, electrical current, magnetic field, or light).

For example, knitted component 132 may include yarns formed of thermoplastic polymer materials (e.g., polyurethane, polyamide, polyolefin, and nylon) that transition from a solid state to a softened or liquid state when subjected to certain temperatures at or above their melting points, and then back to a solid state when cooled. The thermoplastic polymer material may provide the ability to heat and then cool a portion of knitted component 132, thereby forming a region of molten or bonded or continuous material that exhibits certain advantageous properties including, for example, relatively high stiffness, strength, and water resistance.

Knitted component 132 may include a seamless portion that extends from toe region 124, through midfoot region 120, and to heel region 122 on at least one of lateral side 106 and medial side 108 of upper 102. In some embodiments, knitted component 132 may include a first edge (not shown) and a second edge (not shown), which may be the ends of knitted component 132 after the knitting process when knitted component 132 is removed from the knitting machine. After the knitting process, knitted component 132 may be folded or otherwise manipulated such that the first edge and the second edge are secured together at a seam (not shown) during formation of upper 102. The seam may be located on lateral side 106 of upper 102, on medial side 108 of upper 102, and/or at another location (e.g., at a rear portion of heel region 122 of upper 102). Forming upper 102 to have a shape suitable for inclusion in article of footwear 100 may also include lasting upper 102. An example of a lasting process is described in U.S. patent application Ser. No. 12/848,352, filed on 8/2 2010, which is published as U.S. patent No. 8,595,878, which is incorporated herein by reference in its entirety.

When forming knitting member 132, knitting member 132 may be oriented relative to the needle bed of the knitting machine such that toe region 124 is knitted first, followed by midfoot region 120, and then heel region 122 (or vice versa, with heel region 122 knitted first and toe region 124 knitted last). In this embodiment, courses (courses) of knitted component 132 are knitted from medial side 108 to lateral side 106 (and vice versa, from lateral side 106 to medial side 108). In another embodiment, knitting member 132 can be oriented relative to a needle bed of the knitting machine such that a first course of knitting member 132 is knitted to extend from heel region 122 through midfoot region 120 to toe region 124 (or vice versa, wherein the first course of knitting is knitted to extend from toe region 124 through midfoot region 120 to heel region 122). In this second embodiment, courses of knitted component 132 are knitted from heel region 122 to toe region 124 (and vice versa, from toe region 124 to heel region 122). In both embodiments, additional courses are formed parallel to the first course of knitted component 132.

The courses of knitted component 132 may be formed by a single pass (pass) on the knitting machine, or in other words, the courses may be formed by knitting from left to right or right to left across the bed of the knitting machine. In another embodiment, the courses of knitted component 132 may be formed by two passes on the knitting machine, or in other words, the courses may be formed by knitting from left to right and then right to left (or vice versa) across the bed of the knitting machine. Those skilled in the art will understand how to make knitted component 132, whether one pass is referred to as a course or two passes are referred to as courses. Each course may include one or more yarns dispensed from the yarn feeder during each pass.

In some embodiments, each course may include a continuous strand of yarn extending between lateral side 106 and medial side 108 of upper 102 or between heel region 122 and toe region 124. Additionally or alternatively, one or more yarn strands forming at least a portion of each course may extend less than the full length of the first course. For example, it is contemplated that the strands may extend from one side of the upper (e.g., lateral side 106 or medial side 108) to the other side of the upper, but may terminate within the course before reaching the other side. In one non-limiting example, one yarn strand may extend from the outer side 106 toward the inner side 108 when forming the course, but terminate before it reaches the inner side 108. The course may continue toward the inner side 108 in an uninterrupted manner, but additional or alternative different second yarn strands are picked up at the termination of the first yarn. Alternatively, the first strand and the second strand may be combined such that courses are knitted with a combination of the first yarn strand and the second yarn strand.

As shown in fig. 7A-7B (and as described in further detail below), courses of knitted component 132 may at least partially form portions of pods 160, raised structures 128, and/or second region 130. Fig. 3-4 show close-up cross-sectional views of a portion of knitted component 132. While fig. 3 shows a partial cross-sectional view of knitted component 132 prior to being subjected to a stimulus (including, but not limited to, steam or heat, for example), fig. 4 shows a partial cross-sectional view of knitted component 132 after being subjected to a post-manufacturing process or stimulus treatment (including, but not limited to, steam 166).

As shown in fig. 3 and 4, at least a portion of upper 102 (e.g., pods 160) may have a first layer 154, a second layer 156, and an optional third layer 158 (also referred to as a middle layer). Pods 160 are formed from first layer 154 and second layer 156, with first layer 154 and second layer 156 being coextensive and/or overlapping each other and forming pockets 159 therebetween. Pod 160 is bounded on at least one side by second region 130. Third layer 158 is positioned within pocket 159 of pods 160 between first layer 154 and second layer 156, as shown in fig. 3-5. Within pod 160, third layer 158 is secured or otherwise connected to a portion of first layer 154 and a portion of second layer 156 (described in more detail below). The second layer 156, and in some embodiments the third layer 158, of pods 160 form raised structures 128 when stimulated (including, but not limited to, heat, steam, or temperature, for example), as shown in fig. 4 and 5. As shown in FIG. 3, the second layer 156 of pods 160 may be partially raised prior to the application of the stimulus. After the stimulus is applied to form raised structures 128, second layer 156 of pods 160 will further bulge (e.g., move away from first layer 154).

In other portions of upper 102, such as second region 130, a multi-layer knit structure (but including multiple layers in the depicted embodiment) is not required. In the second region 130, as shown in fig. 3-5, the first layer 154 and the second layer 156 are at least partially coextensive and/or overlapping and are connected to each other in at least one portion, and the third layer 158 floats or is embedded between the first layer 154 and the second layer 156 (described in more detail below). As described above, as shown in fig. 4-5, the height or thickness 130a and width 130b of the second region 130 are less than the height or thickness 128a and width 128b of the raised structures 128. Thus, when knitted component 132 is stimulated, second region 130 does not form raised structures 128 due to the configuration of first layer 154, second layer 156, and third layer 158 within second region 130, the connection of first layer 154 and second layer 156 within second region 130, and the lack of connection of third layer 158 with first layer 154 and second layer 156 within second region 130, due to the size of second region 130.

At least in pods 160, both first layer 154 and second layer 156 may be formed from the loop structure of knitted component 132 such that they are formed primarily on a knitting machine. The third layer 158 is also formed on the knitting machine primarily with the first layer 154 and the second layer 156. However, as described in more detail below, third layer 158 may generally lack a loop knit structure (i.e., intermeshed loops) at least within pods 160, and thus may float at least partially between first layer 154 and second layer 156. In some embodiments, the third layer 158 may be secured to at least one of the first layer 154 and the second layer 156 via tuck stitches and/or loops. For example, in each of fig. 3-5, in the raised structures 128, the third layer 158 is secured to a portion of the first layer 154 at a first location 162a within the pocket 159 and to a portion of the second layer 156 at a second location 164a within the pocket 159. In each of the second regions 130, the third layer 158 can be formed as embedded strands between opposing surfaces of the knitted component 132 as shown, but alternatively, the third layer 158 can be incorporated into one or more layers of knitted loops of the second region 130.

When knitted component 132 is included in upper 102, second layer 156 may form a portion of an exterior surface of upper 102 and first layer 154 may form a portion of an interior surface of upper 102. In one embodiment, as shown in fig. 3-5, second layer 156 forms a portion of an exterior surface of upper 102 at each of raised structures 128 and forms a portion of an interior surface of upper 120 at each of second areas 130. First layer 154 forms a portion of an interior surface of upper 102 at each of raised structures 128 and forms a portion of an exterior surface of upper 120 at each of second areas 130.

Each of the raised structures 128 may be separated on at least one side by a second region 130. As shown in fig. 1-2, raised structures 128 may be parallel or substantially parallel to each other along a "first direction" a (where direction a is a "lateral" direction, or a direction that is substantially parallel to a longitudinal direction extending through courses of knitted component 132). In the depicted embodiment, direction a is illustrated as a medial-to-lateral direction, generally along the y-axis as shown in fig. 2, but courses may alternatively extend through a different direction of knitted component 132. The raised structures 128 may also (or alternatively) be parallel or substantially parallel to each other along a "second direction" B, which may be a longitudinal direction (illustrated as a heel-to-toe direction, substantially along the x-axis as shown in fig. 2) perpendicular to direction a. In alternative embodiments, as shown in fig. 5-7B, the raised structures 128 may be offset from one another along either the first direction a or the second direction B and substantially parallel to one another along the other of the first direction a and the second direction B. As shown in the cross-sectional side view of FIG. 5, the raised structures 128 are parallel or substantially parallel to one another along a first direction A and offset from one another along a second direction B. In alternative embodiments, the raised structures 128 may be parallel or substantially parallel to each other along the second direction B and offset from each other along the first direction a. When knitted component 132 is formed on a knitting machine, first direction a may be substantially parallel to a needle bed. In an alternative embodiment, the second direction B may be substantially parallel to the needle bed when the knitted component 132 is formed on the knitting machine.

Various processes for creating raised structures 128 are contemplated, and these processes may occur during or after the knitting process used to form knitted component 132. For example, upper 102 may be knitted on a knitting machine having a front bed and a rear bed. In one example, yarns knitted in the back bed may ultimately form a first layer 154 of knitted component 132, and yarns knitted in the front bed may ultimately form a second layer 156 of knitted component 132. The yarn may float through the needles of the knitted component 132 to form the third layer 158 and tuck to one of the needles on the back bed to connect the third layer 158 with the first layer 154 and to one of the needles on the front bed to connect the third layer 158 with the second layer 156.

One or more yarns may be used in knitting knitted component 132. In one non-limiting example, first yarn may be used to form first knitted layer 154 of knitted component 132 (at least in pods 160), first knitted layer 154 forming at least a portion of first side 134 of knitted component 132, at least a portion of first side 134 forming an interior surface of upper 102. The first yarn may comprise, for example, a relatively elastic yarn. One or more warp yarns (ends) of the first yarn may be used, such as one warp yarn or two or more warp yarns. Preferably, in this example, one warp yarn of the first yarn may be used. In one non-limiting example, the first yarn may be an "EO4" type yarn supplied by instrumented yuhui corporation (Unifi, inc.) located in green, north carolina, which preferably has relatively high elasticity compared to other yarns that may be used to form knitted component 132. The first yarn may include a spandex core (i.e., lycra) wrapped with polyester. It may have a denier range of about 800D to about 1050D, a tensile strength of greater than 0.75kgf (kilogram force) and an elongation of 180% to 250%. Denier is the unit of measure of the linear density of a fiber, measured in grams per 9000 meters. In some embodiments, for example when it is desired that the first yarn reduce in size during the manufacturing process, the shrinkage of the first yarn (also referred to as the first shrinkage) may be higher when heated (or otherwise stimulated) than other yarns used to form knitted component 132. In other words, for example, when heated (e.g., via steam), the first yarn may shrink more and/or have a higher shrinkage than other yarns used to form knitted component 132. In one example, the shrinkage of EO4 from the instrumented yuhui corporation was tested using a standard jacquard square program and the results are provided in the table below.

The second yarns may be used to form a second knitted layer 156 of knitted component 132, second knitted layer 156 forming at least a portion of second side 136 of knitted component 132, at least a portion of second side 136 forming an exterior surface of upper 102. The second yarn may be the same as or different from the first yarn. In one example, the second yarns used to form at least a portion of second side 136 of knitted component 132 (which forms at least a portion of an exterior surface of upper 102 in at least pods 160) are yarns having different characteristics relative to the first yarns. The second yarn may comprise a combination of materials or strands. One or more warp yarns of the second yarn may be used, such as one warp yarn, two warp yarns, or more than two warp yarns. For example, the second yarn may comprise a combination of one warp yarn of a "monofilament" yarn and one warp yarn of a yarn formed of a thermoplastic polymer material (sometimes referred to as a fusible yarn).

The monofilament yarn of the second yarn may be supplied by the tin guard corporation of taiwan (Formosa Ting Sho) and may be referred to as 0.125mm monofilament nylon, which may have relatively low elasticity compared to the first yarn that may be used to form knitted component 132. The monofilament yarns of the second yarns may expand or have a low to minimal shrinkage when subjected to a stimulus (e.g., temperature, heat, or steam). The monofilament yarns may have a denier in the range of about 125D to about 150D, a tensile strength of about 0.8kgf to 1.2kgf (kgf) and an elongation of 16% to 25%. As described above, denier is the unit of measure of the linear density of a fiber, measured in grams per 9000 meters.

The fusible yarn of the second yarn may be manufactured by EMS-Griltech corporation of switzerland, which may also have relatively low elasticity compared to other yarns that may be used to form knitted component 132. Fusible yarns are low melting yarns that provide stiffness, structure, and strength to knitted component 132 upon being stimulated (e.g., temperature, heat, or steam). The fusible yarn has a melting temperature of 65 degrees celsius, may have a denier (explained above) in the range of about 140D to about 170D, a tensile strength of greater than 0.375 (kilogram force) and an elongation of 53% to 74%. Different colored fusible yarns may be used. In one example, the fusible yarn may have a translucent color such that when a stimulus (e.g., temperature, heat, or steam) is applied to the second yarn, the fusible yarn melts, which causes the second yarn to become more translucent such that the color of the yarns of third layer 158 is visible from the exterior surface of upper 102. The fusible yarn of the second yarn may expand or have a low to minimal shrinkage when subjected to a stimulus (e.g., temperature, heat, or steam).

The shrinkage of the second yarn upon exposure to steam (or another stimulus), also referred to as the second shrinkage, is relative to the first shrinkage of the first yarn forming knitted component 132. In other words, when subjected to similar amounts of heat (e.g., such as via temperature, heat, or steam), the second yarn may shrink far less (if any), have a lower shrinkage than the first shrinkage of the first yarn used to form knitted component 132, and/or expand. For example, the combination of materials that together form the monofilament yarn and the fusible yarn of the second yarn may be achieved by twisting, winding, braiding, and/or winding onto another yarn, etc., and/or the yarn may be in a core/sheath configuration and/or the yarn may be secured at multiple points along its length. In one example, 0.125mm monofilament yarns (supplied by Hi-Tech, korea) and fusible yarns (supplied by EMS-Griltech) were tested for shrinkage using a standard jacquard square program, and the results are provided in the following table.

In addition to the first yarn and the second yarn used to form knitted component 132, a third yarn may be used to form third layer 158 of knitted component 132. The third yarn may be the same as the first yarn and/or the second yarn, or may be different. In one example, the third yarn used to form at least a portion of knitted component 132 includes a different yarn than the first yarn and the second yarn. In one example, the third yarn is relatively less elastic than the first yarn (E04) and may have the same elasticity, less elasticity, or more elasticity as the second yarn (which may be monofilament and fusible as described above). The third yarn may be a combination of materials or strands. One or more warp yarns of the third yarn may be used, such as one warp yarn, two warp yarns, or more than two warp yarns.

For example, the third yarn may comprise a combination of three warp yarns of the "monofilament" type yarn and one warp yarn of the "high tenacity" type yarn. The monofilament yarns may have the same characteristics as the monofilament yarns used in the second yarns described above. Similar to the filaments of the second yarn, the filaments of the third yarn may expand or have a low to minimal shrinkage when subjected to a stimulus (e.g., temperature, heat, or steam). High tenacity yarns are available from the new century corporation of the far east, taibei, taiwan, china (Far Eastern New Century). The high tenacity yarns are polyester yarns that may comprise a plurality of yarn filaments and impart various aesthetic and color characteristics to knitted component 132. The high tenacity yarn has a melting point of about 210 degrees celsius. The shrinkage of the third yarn (when subjected to steam or other stimulus), also referred to as the third shrinkage, may be lower relative to the first shrinkage of the first yarn and may be greater, lesser, or equal relative to the second shrinkage of the second yarn used to form knitted component 132 when heated or otherwise stimulated. In other words, the third yarn may shrink far less (if any), have a lower shrinkage than the first shrinkage of the first yarn, and/or expand when subjected to similar amounts of heat (e.g., such as via temperature, heat, or steam). Moreover, the third yarn may shrink relatively more, less, or the same than the second yarn. In one example, a combination of materials, such as monofilament yarns and high tenacity yarns that together form the third yarn, may be achieved by parallel coexistence. In other embodiments, the combination of materials may be achieved by twisting, winding, braiding, and/or winding on another, etc., and/or the yarns may be in a core/sheath configuration and/or the yarns may be fixed at multiple points along their length. In one example, shrinkage of 0.125mm monofilament yarns (supplied by Hi-Tech corporation in Korea) and high tenacity yarns (supplied by New century corporation in the far east) were tested using a standard jacquard square program, and the results are provided in the following table.

During or after the knitting process, a stimulus, such as heat, may be applied to at least a portion of upper 102 or the entire upper 102. The heat may be in the form of steam, for example, by a steam gun or other steam providing device. Exposure of knitted component 132 to steam 166 can produce one or more effects.

In one example, steam 166 may cause one or more yarns used to form knitted component 132 to shrink at different relative rates, thereby forming raised structures 128, as shown in fig. 4. For example, steam 166 may cause the first yarn (e.g., E04 yarn) to shrink to a higher degree and/or rate than the second and third yarns used to form knitted component 132. In one example, the second yarn (e.g., monofilament and fusible yarn) may also shrink in response to the steam 166 stimulus, but shrink less than the first yarn. The second yarn has relatively little or no significant shrinkage in response to the stimulus, and the second yarn is also expandable when stimulated. The third yarns (e.g., monofilaments and high tenacity yarns) also have relatively little or no significant shrinkage in response to steam 166 stimulation, and the third yarns may also expand when stimulated. The shrinkage and potential expansion of the first, second, and third yarns may result in the total shrinkage of knitted component 132. In one example, after the stimulus is applied, the total shrinkage of knitted component 132 includes an average shrinkage of 10% along the length (x: toe to heel) of knitted component 132 and an average shrinkage of 14.25% along the width (y: rear side to front side).

As shown in fig. 3-5, the first yarns forming first knitted layer 154 may be used to form at least a portion of first side 134 of knitted component 132, and thus form an interior surface (e.g., facing the cavity) of upper 102 at pods 160 (and under raised structures 128) of upper 102. The first yarn may also be used to form at least a portion of second side 136 of knitted component 132, thereby forming an exterior surface of upper 102 at second region 130. The second yarns forming second knitted layer 156 may be used to form at least a portion of second side 136 of knitted component 132, at least a portion of second side 136 forming an exterior surface of upper 102 at pods 160 or raised structures 128 of upper 102. The second yarns may also be used to form at least a portion of first side 134 of knitted component 132, at least a portion of first side 134 forming an interior surface of upper 102 at second region 130. Prior to exposing knitted component 132 to the stimulus (see fig. 3), second side 136 may be substantially planar, overlapping, and substantially coextensive with first side 134. Alternatively, before exposing knitted component 132 to the stimulus, raised structures 128 of pods 160 may be partially visible as shown in fig. 3 (e.g., because more courses are used to form second side 136 during knitting than first side 134), but are not as apparent and/or defined as shown in fig. 4-5, fig. 4-5 showing one example of knitted component 132 after exposure to the stimulus. When exposed to a stimulus such as steam 166, the first yarns of first knitted layer 154 contract, while the second yarns on second knitted layer 156 and the third yarns of third layer 158 of knitted component 132 each have relatively little or no significant contraction. In one example, the second yarn of the second knit layer 156 and the third yarn of the third layer 158 can be expanded. The contraction of the first yarn causes the second yarn to flex or bulge outwardly as shown by the arrows in fig. 5-6 and 4 to form a raised structure 128 extending outwardly and away from the first side 134 of knitted component 132. The expansion of the second and third yarns may also enhance the bending/bulging of the second side 134 as the second and third yarns expand. In other words, the relative differences in shrinkage and expansion of the different yarns used to form knitted component 132 upon exposure to the stimulus results in the formation or reinforcement of raised structures 128.

As shown in fig. 3-5, more than one third yarn may form a third layer 158 of knitted component 132. In one example, in the side cross-sectional views of fig. 3-5, two of the third yarns forming third layer 158 include a first portion 158a of the third yarns and a second portion 158b of the third yarns, which may cross each other and form an "X" configuration within pods 160 or raised structures 128 when viewed from the side cross-sectional view. In one example, the first portion 158a and the second portion 158b of the third yarn have the same characteristics, or in another example, the first portion 158a and the second portion 158b of the third yarn may have the same or similar characteristics, except for one or more characteristics, such as color. As shown in fig. 3-5, first portion 158a and second portion 158b of the third yarn float through knitted component 132 in second region 130, in this embodiment, and are therefore not secured to first layer 154 and second layer 156 in second region 130, but alternatively, third yarn 158 may form intermeshed loops at least partially in second region 130.

Within pods 160 or raised structures 128, a third yarn may be secured to first layer 154 and second layer 156 via tuck stitches and/or loops. The first portion 158a of the third yarn may be secured to a portion of the second layer 156 via tuck stitch and/or loop at the second location 164a, and the second portion 158b of the third yarn may be secured to a portion of the first layer 154 via tuck stitch and/or loop at the first location 162 a. The first portion 158a and the second portion 158b of the third yarn then cross each other within the pocket of the clip 160. The first portion 158a of the third yarn may then be secured to a portion of the first layer 154 via tuck stitch and/or loop at a third location 162b, and the second portion 158b of the third yarn may be secured to a portion of the second layer 156 via tuck stitch and/or loop at a fourth location 164 b. Securing the third yarn to first layer 154 and second layer 156 via tuck stitch and/or loops ensures placement and positioning of third layer 158 within pods 160.

As discussed above, in one example, the second yarn may be translucent or transparent (at least after a stimulus such as a heat treatment is applied to knitted component 132), and the third yarn may have a color that is visible on an exterior surface of upper 102 through raised structures 128. The positioning of the third yarn may vary within raised structures 128 such that the color of the third yarn is visible at different points of view on the exterior surface of upper 102. For example, first portion 158a of the third yarn may have a different color than second portion 158b of the third yarn such that the color of first portion 158a of the third yarn is visible through the exterior surface of upper 102 at one point of view or location and the color of second portion 158b of the third yarn is visible through the exterior surface of upper 102 at a different point of view or location. Thus, by selective positioning of third yarn, including second layer 156 and raised structures 128 where the third yarn is secured within pods 160, different colors are visible through the exterior surface of upper 102.

Turning now to fig. 6 and 7A-7B, a knitting procedure for forming knitted component 132 will be described, knitted component 132 including one or more pods 160 to form raised structures 128 and second region 130. First, FIG. 6 shows an annotated top view of knitted component 132 that reflects a second side 136 of knitted component 132 (which may form an exterior surface of upper 102 when knitted component 132 is incorporated into article of footwear 100). The portions of knitted component 132 depicted in pink (e.g., dashed lines in the black and white drawing) adjacent portions "1" and "2" correspond to the exploded view of the knitting procedure shown in fig. 7A. This section will be referred to herein as sections 1-2. The portions of knitted component 132 depicted in blue (e.g., the solid black line in the black and white drawing) adjacent portions "3" and "4" correspond to the exploded view of the knitting procedure shown in fig. 7B. This portion will be referred to herein as portions 3-4. Together, portions 1-2 and 3-4 reflect the offset configuration of pods 160 forming raised structures 128 as described above and shown in FIG. 5. In addition to pods 160 described herein, portions 1-2 also reflect second region 130. Portions 3-4 reflect two halves of adjacent pods 160, with second region 130 between the two halves of adjacent pods 160. In other words, as compared to FIG. 3, portions 3-4 show second region 130 in the middle of FIG. 3, as well as half of pods 160 to the left of second region 130 and half of pods 160 to the right of second region 130.

In fig. 6, the light green yarns (shown in light gray in the black and white figures) reflect the yarns of second layer 156 that form a portion of second side 136 of knitted component 132 or the exterior surface of upper 102. The orange yarn (shown black in the black-and-white figures) reflects the yarn of first layer 154, which yarn of first layer 154 forms a portion of second side 136 of knitted component 132 or the exterior surface of upper 102 at second region 130 of knitted component 132.

Turning to section 1-2 shown in fig. 6 and 7A, knitted component 132 is formed from a plurality of courses and wales. In weft knitting, the wales are perpendicular to the courses of the yarn. The wales of portions 1-2 and 3-4 within knitted component 132 are numbered 170-x, where "x" reflects the respective wale, particularly wales 1 through 12. In this example, the number of wales is the same as the number of needles in the needle bed of the knitting machine. The needles are indicated by dots in fig. 7A to 7B. As shown in FIG. 7A, the courses for portion 1-2 within knitted component 132 are numbered "172-x," where "x" reflects each course, particularly courses 1 through 16. In this embodiment, to produce one course, e.g., 172-1, two passes are made on the knitting machine, e.g., left to right along the bed of the knitting machine and then right to left. As described above, in alternative embodiments, one course may be created by one pass (e.g., left to right or right to left) on the knitting machine. In the example shown in fig. 6 and 7A, the portions 1-2 are formed of 16 courses and 12 wales. The 16 courses produce 8 rows of first side 134 of knitted component 132 and 8 rows of second layer side 136 of knitted component 132. The 8 rows of second side 136 of knitted component 132 are shown in fig. 6 and labeled "row x," where x reflects the corresponding rows of rows 1 through 8. In alternative embodiments, the number of courses may be reduced to reduce the size of pods 160, or the number of courses may be increased to increase the size of pods 160. In other words, when pods 160 form generally spherical raised structures 128 having a first diameter extending in first direction A and a second diameter extending in second direction B, the number of courses may be reduced to reduce the second diameter of raised structures 128 or the number of courses may be increased to increase the second diameter of raised structures 128. Also, in this example, the number of wales per pod 160 may be reduced to reduce the first diameter of the raised structures 128, or may be increased to increase the first diameter of the raised structures 128.

In FIG. 7A, a first course 172-1 of knitted component 132 is formed to produce a first portion of second layer 156 of knitted component 132, and a second course 172-2 of knitted component 132 is formed to produce a first portion of first layer 154-1 of knitted component 132. A first portion of the second layer 156 is labeled 156-1 in fig. 7A and a first portion of the first layer 154 is labeled 154-1 in fig. 7A. In the first pass of the first course 172-1, every other needle on the front needle bed of the knitting machine is used to knit the second layer 156-1. In the second pass of the first course 172-1, the second layer 156-1 is knitted with every other needle on the front needle bed of the knitting machine (specifically, with the needles skipped in the first pass of the first course 172-1) except for the first needle shown by the first wale 170-1 of the first layer 154-1 and the second layer 156-1 by knitting the loops 180 of the first course 172-1 on the back needle bed of the knitting machine. More than two passes of the first course 172-1 may be utilized (e.g., such that more knitted material is formed on the second side 136 of the knitted component 132 to enhance the loft of the raised structure 128).

In the first pass of the second course 172-2, every other needle on the back needle bed of the knitting machine is used to knit the first layer 154-1. In the second pass of the second course 172-2, the first layer 154-1 is knitted on the back needle bed of the knitting machine with every other needle (specifically, with the needles skipped in the first pass of the second course 172-2) in addition to the first needles shown by the first wale 170-1 of the first needle bed of the knitting machine that knit the first layer 154-1 on the front needle bed (e.g., by knitting the loop 182 of the second course 172-2 on the front needle bed at a location corresponding to the loop 180). Anchoring the first layer 154-1 and the second layer 156-1 formed on the front and rear needle beds can create the above-described second region 130 separating the individual pods.

First layer 154-1 is knitted on the front needle bed and second layer 156-1 is knitted on the back needle bed, forming a portion of one of second regions 130 such that first layer 154-1 forms a portion of second side 136 of knitted component 132 (and an exterior surface of upper 102) and second layer 156-1 forms a portion of first side 134 of knitted component 132 (and an interior surface of upper 102). Thus, in a portion of the second region 130, the first layer 154-1 and the second layer 156-1 are fixed to each other, and the third layer 158 floats between the first layer 154 and the second layer 156 (as described below).

As shown in fig. 7A, to form a third layer 158 positioned between the first layer 154-1 and the second layer 156-1, two passes on the knitting machine (e.g., left to right and right to left) are also completed. This portion of the third layer 158 is labeled 158-1 in FIG. 7A. In the first pass, the yarn of the third layer 158-1 floats past the first three needles and then is tucked onto the back needle bed on the fourth needle to secure the third layer 158-1 to the first layer 154-1 of the knitted component 132 at the first location 162 a. The yarn of the third layer 158-1 then floats past the fifth through ninth needles and is then tucked on the tenth needle to the front needle bed to secure the third layer 158-1 to the second layer 156-1 at the second location 164 a. The yarn of the third layer 158-1 then floats past the eleventh through twelfth needles to complete the first pass. In the second pass, the yarn of the third layer 158-1 floats again through the twelfth to eleventh needles and then is tucked on the tenth needle to the back needle bed to secure the third layer 158-1 to the first layer 154-1 at the third location 162 b. The yarn of the third layer 158-1 then floats past the ninth through fifth needles and then is tucked onto the front needle bed at the fourth needle to secure the third layer 158-1 to the second layer 156-1 of the knitted component 132 at the fourth location 164 b. The yarn of the third layer 158-1 then floats through the third to first needle to complete the second pass. The two passes create an "X" -configuration of third layer 158-1 within pods 160 as shown in FIGS. 3-5. In alternative embodiments, the location at which the yarns of the third layer 158-1 are secured to the first layer 154-1 or the second layer 156-1 may vary.

After knitting first course 172-1 and second course 172-2 and floating third layer 158-1 through and securing to first layer 156-1 and second layer 154-1 via tuck stitch, third course 172-3 of knitted component 132 is formed to create a second portion of second layer 156 of knitted component 132 and fourth course 172-4 of knitted component 132 is formed to create a second portion of first layer 154 of knitted component 132. The second portion of the second layer 156 is labeled 156-2 in FIG. 7A and the second portion of the first layer is labeled 154-2 in FIG. 7A. In the first pass of the third course 172-3, every other needle on the front needle bed of the knitting machine is used to knit the second layer 156-2. In the second pass of the third course 172-3, every other needle (specifically, the needle skipped in the first pass of the third course 172-3) is used to knit the second layer 156-2. The second portion of the second layer 156-2 knitted in the third course 172-3 is knitted only on the front needle bed of the knitting machine as compared to the first portion of the second layer 156-1 knitted in the first course 172-1.

In the first pass of the fourth course 172-4, every other needle on the back needle bed of the knitting machine is used to knit the first layer 154-2. In the second pass of the fourth course 172-4, every other needle (specifically, the needle skipped in the first pass of the fourth course 172-4) is used to knit the first layer 154-2 on the back needle bed of the knitting machine. The second portion of the first layer 154-2 knitted in the fourth course 172-4 is knitted only on the back needle bed of the knitting machine as compared to the first portion of the first layer 154-1 knitted in the second course 172-2. In this example, the second portion of the first layer 154-2 and the second portion of the second layer 156-2 are not fixed to each other at the first needles of the knitting machine. Also, in this example, the third layer 158 is not secured to the second portion of the first layer 154-2 or the second portion of the second layer 156-2. In other embodiments, the second portion of the first layer 154-2 and the second portion of the second layer 156-2 may be fixed to each other. Moreover, in other embodiments, the third layer 158 may be secured to the second portion of the first layer 154-2 and the second portion of the second layer 156-2.

As shown in FIG. 7A, knitting the first course 172-1, the second course 172-2, the third course 172-3, and the fourth course 172-4, and the pattern that floats and secures the third layer 158-1 to the first layer 154-1 and the second layer 156-2 via tuck stitches, is then repeated in fifth through eighth courses (172-5, 172-6, 172-7, 172-8), ninth through twelfth courses (172-9, 172-10, 172-11, 172-12), and thirteenth through sixteenth courses (172-13, 172-14, 172-15, and 172-16).

First course 172-1 and second course 172-2 each produce a first row or a portion of a "row-1" of a first row of second side 136 of knitted component 132, and a portion of first side 134 of knitted component 132, as shown in fig. 6. Third stitch row 172-3 produces a second row or "row-2" of second side 136 of knitted component 132 as shown in fig. 6, and fourth stitch row 172-4 produces a second row of first side 134 of knitted component 132. As described above, the knitting pattern is repeated such that sixteen courses are formed with 8 rows being formed on first side 134 of knitted component 132 and 8 rows being formed on second side 136 of knitted component 132, as shown in fig. 6. Also, as described above, in alternative embodiments, the number of courses and corresponding rows may be reduced to reduce the size of pods 160 (and thus raised structures 128) or increased to increase the size of pods 160 (and thus raised structures 128).

In fig. 7A-7B, the light green yarns (shown as white courses in black and white) reflect the yarns of second layer 156 that form a portion of second side 136 of knitted component 132 or the exterior surface of upper 102 at pods 160 and a portion of first side 134 of knitted component 132 or the interior surface of upper 102 at second regions 130. Orange yarns (shown as closely spaced left-angled hash lines in the black and white figures) and blue yarns (shown as right-angled hash lines in the black and white figures) reflect yarns of first layer 154 that form a portion of second side 136 of knitted component 132 or an outer surface of upper 102 at second region 130 of knitted component 132. At pods 160 of knitted component 132, orange yarns (left-angled hash lines) and blue yarns (right-angled hash lines) form a portion of first side 134 of knitted component 132 or an interior surface of upper 102. The dark green color (shown as widely spaced left-angled hash lines in black and white) and the red yarn (shown as solid dark gray in black and white, adjacent to the dark green color (e.g., widely spaced left-angled hash lines)) reflect the yarns of the third layer 158 positioned between the first layer 154 and the second layer 156 of the knitted component 132.

As described above, section 1-2 reflects second region 130 and pods 160, which together form a portion of knitted component 132. As shown in fig. 6 and 7B, portions 3-4 form part of a subsequent row of knitted component 132. However, as shown in FIG. 6, the orange yarn (shown as closely spaced left-hand hash lines in black and white) reflecting the second region 130 where the first layer 154 was knitted on the front needle bed and the second layer 157 was knitted on the back needle bed is positioned approximately in the center of the portions 3-4. This configuration reflects the offset configuration of pods 160 (forming raised structures 128), as shown in fig. 5. Thus, the knitting order of the POD3-4 portion differs from the portion 1-2 in two ways. First, the first layer 154 switches knitting on the back needle bed to the front needle bed at the seventh needle shown in the seventh wale 170-7 of fig. 7B, but not at the first needle shown in the first wale 170-1 of fig. 7A. Second, the second layer 156 is switched from knitting on the front stitch bed to knitting on the rear stitch bed at the seventh needle shown in the seventh wale 170-7, rather than at the first needle shown in the first wale 170-1 of fig. 7A as part 1-2. As previously described, this knitting sequence creates the second region 130 such that the second region is formed approximately in the center of the portion 3-4 rather than at the beginning of the portion 1-2. In addition to the differences described above, the knitting sequences and features used to describe portions 1-2 are also applicable to portions 3-4.

In the example shown in FIG. 6, second region 130 delimits pods 160 along the left side of pods 160 and the right side of pods 160, in other words, along wale side direction or second direction B of knitted component 132. Second region 130 does not demarcate the entire top and bottom sides of pods 160 or along the course direction or first direction a of knitted component 132. Instead, second region 130 forms a fixed point along the top and bottom sides of pods 160. In alternative embodiments, second regions 130 may also extend along the entire top and/or bottom sides of pods 160, or along the course of first direction A of knitted component 132, such that pods 160 are surrounded by second regions 130 on each side of pods 160.

The knitting sequence of fig. 7A-7B can be repeated as necessary to form a knitted component having the appropriate dimensions. Furthermore, it should be noted that the order may be changed to include different features by changing certain knitting structures, by changing yarn types, by increasing or decreasing the number of courses per step, or by making any other suitable adjustment to the knitting process or materials used. In addition, other sequences may be used before, after, or between the sequences of fig. 7A-7B.

Although embodiments and other features of raised structures 128 are generally described herein with reference to upper 102 of an article of footwear, those features may additionally or alternatively be incorporated into another type of article. For example, the knitted raised structures 128 may be included in articles of apparel (e.g., shirts, pants, socks, footwear, jackets and other outerwear, briefs and other undergarments, hats and other headwear), cases (e.g., backpacks, bags), and upholstery for furniture (e.g., chairs, sofas, car seats).

In the present disclosure, ranges given in absolute terms or in approximate terms are intended to encompass both, and any definitions used herein are intended to be clear and not limiting. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the embodiments are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, all ranges disclosed herein are to be understood to encompass any and all subranges subsumed therein (including all fractional and integer values).

Further, the present disclosure encompasses any and all possible combinations of some or all of the various aspects described herein. It should also be understood that various changes and modifications to the aspects described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present disclosure and without diminishing its intended advantages. Accordingly, such changes and modifications are intended to be covered by the appended claims.

Claims

1. A knitted component comprising:

a pocket formed between the first knit layer and the second knit layer; and

a yarn positioned at least partially within the pocket between the first knit layer and the second knit layer, the yarn comprising a first strand and a second strand, the second strand having at least one different characteristic than the first strand,

wherein the first strand of the yarn is secured to the second knit layer at a first location within the pocket and to the first knit layer at a second location within the pocket,

wherein the second strand of the yarn is secured to the first knit layer at a third location within the pocket and to the second knit layer at a fourth location within the pocket, and

wherein the first strand and the second strand of the yarn form an x-shaped configuration within the pocket.

2. The knitted component of claim 1, wherein the first strand of the yarn and the second strand of the yarn are different colors.

3. The knitted component of claim 1, wherein the first strand of the yarn and the second strand of the yarn have different material compositions.

4. The knitted component of claim 1, wherein the first strand of the yarn and the second strand of the yarn are secured to the first knit layer and the second knit layer within the pocket via tuck stitches.

5. The knitted component of claim 1, wherein the second knitted layer forms a raised structure by extending away from the first knitted layer when the knitted component is stimulated.

6. The knitted component of claim 1, wherein the first knitted layer and the second knitted layer are secured to one another adjacent a second region of the pocket.

7. A knitted component comprising:

A third yarn at least partially within a pocket formed between the first knit layer and the second knit layer, the third yarn comprising a first strand and a second strand separated from the first strand in at least a portion of the pocket, the second strand of the third yarn having different characteristics than the first strand;

wherein the third yarn is secured to the first knit layer at a first location and a second location within the pocket and to the second knit layer at a third location and a fourth location within the pocket such that the third yarn forms an x-shaped configuration within the pocket.

8. The knitted component of claim 7, wherein the first strand of the third yarn and the second strand of the third yarn are different colors.

9. The knitted component of claim 7, wherein the first strand of the third yarn and the second strand of the third yarn have different material compositions.

10. The knitted component of claim 7, wherein the second knitted layer forms a raised structure by extending away from the first knitted layer when the knitted component is subjected to the stimulus.

11. The knitted component of claim 10, wherein the third yarn is visible through the second knitted layer at the raised structure of the knitted component.

12. The knitted component of claim 10, wherein the raised structure forms a spherical shape.

13. The knitted component of claim 7, wherein the first knitted layer and the second knitted layer are secured to one another adjacent a second region of the pocket.

14. The knitted component of claim 7, wherein the third yarn is secured to the first knitted layer and the second knitted layer within the pocket by tuck stitches.

15. A knitted component comprising:

a plurality of raised structures each formed from a first knitted layer and a second knitted layer at least partially coextensive with each other, each raised structure including a pocket where the second knitted layer extends away from the first knitted layer,

a yarn positioned at least partially within the pocket of each raised structure, the yarn comprising a first strand and a second strand, the second strand having at least one different characteristic than the first strand,

Wherein the first strand of the yarn is secured to the second knit layer at a first location within the pocket of each raised structure and to the first knit layer at a second location within the pocket of each raised structure,

wherein the second strand of the yarn is secured to the first knit layer at a third location within the pocket of each raised structure and to the second knit layer at a fourth location within the pocket of each raised structure, and

wherein the first strand of the yarn and the second strand of the yarn form an x-shaped configuration within the pocket of each raised structure.

16. The knitted component of claim 15, wherein the first knitted layer includes a second yarn and the second knitted layer includes a third yarn that has a lower shrinkage than the second yarn when stimulated.

17. The knitted component of claim 15, wherein the first strand of the yarn and the second strand of the yarn are different colors.

18. The knitted component of claim 15, wherein the second knitted layer forms at least a portion of an exterior surface of an upper.

19. The knitted component of claim 15, wherein the yarn is visible through the second knitted layer at least at some of the plurality of raised structures.

20. The knitted component of claim 15, wherein the yarn is secured to the first knitted layer and the second knitted layer within the pocket by tuck stitches.